Foundation Fieldbus System Design and Engineering of CSPC Nanhai Project

Transcription

1 Foundation Fieldbus System Design and Engineering of CSPC Nanhai Project Stephen Weng MAC Chief System Integration Engineer ISD-MASP-S05008 Copyright Yokogawa Electric Corporation February 18, 2005

2 Background Site Location BEIJING SHANGHAI HUIZHOU, DAYA BAY HONG KONG CSPC Project Location 2

3 Owner CNOOC (China National Offshore Oil Corp.) SHELL PMC (Project Management Contractor) BSF (BECHTEL-SEI-FOSTER WHEELER) MAC (Main Automation Contractor) YOKOGAWA The project is one of the largest site of FF device installation Total FF Device :16,000 Background 3

4 CSPC Main Process Units Background 4

5 CSPC Products Overview Background 5

6 Yokogawa Supply Scope An Integrated Control System including: Distributed Control System (DCS) Instrumented Protection System (IPS) Fire & Gas Detection System (FGS) Movement Automation System (MAS) Plant Resource Management System (PRM) Operational Data System (ODS) Operator Training System (OTS) Analyser Management and Data Acquisition System (AMADAS) CCTV DCS Anywhere Interfaces to 3 rd Party Systems Background 6

7 Project Structure and Yokogawa MAC Role Client CNOOC & Shell Petrochemicals Complex (CSPC) Background PAG PMC Bechtel-Sinopec-Foster Wheeler (BSF) MAC EPC-1 EPC-2 EPC-X PAG (Plant Automation Group): Includes member from CSPC and BSF, a bridge between EPC & MAC for all design approval 7 MAC: In charge of total system integration and design/engineering consistency

8 FF Technology in CSPC Nanhai <DCS/PRM thin Client via IE> Business Domain Users <PRM Servers & Diagnostic Servers> <DCS/PRM thin Client> Integrated Control Systems Application Servers (including Data Historian) Industrial IT (Bridge) Business Domain (IT System Network) <DCS/PRM thin Client via IE> Outside Users from Business Domain Technical Domain (Control System Network) Field Devices (Field Network Information) <FF & HART Devices> 8 Business Domain Mobile Users (Wireless Devices Outdoor Use in the Complex) <DCS/PRM Client via IE>

9 Conventional and FF Difference Conventional I/O Multi-Core Cable I/O Module Field Device Marshalling Rack (MDF) Local JB FF I/O H1 Interface Module H1 Cable LAS Local JB Terminator Power Supply FB FF Device 9

10 Conventional and FF Difference Conventional I/O System 1) Analog (4-20mA) 2) 1 :1 Cable Connection 3) Function Block in DCS FF System 1) 2 way Digital Communication Communication Cycle LAS Allocation Cable Spec.& Cable Length 2) Multi-Drop Cable Connection Device Grouping Wiring Topology JB Configuration & Location Power Supply for Multi Devices No Marshalling Function in MDF 3) Function Block in Device&DCS Basic Function Block Advanced Function Block Multi-vendors Devices 10

11 FF technology relatively new, especially in large scale implementation Many parties involved (CSPC, PMC, MAC, Multiple EPCs, Package Vendors, Subcontractors, etc) Multiple Engineering Methodology Different Skill Sets/Experiences Huge Work Volumes and Concurrent Engineering The Challenges 11

12 The Solutions As MAC, Yokogawa is able to directly work with CSPC and PMC/PAG to provide the following key solutions: Dedicated Project FF Design Specification FF Data Exchange Mechanism Specification FF Device HIST Test FF Pilot System FF Training FF Site Workshop FF Loop Check Guideline 12

13 Engineering Methodology Early Involvement Specification Phase Configuration Phase Staging Phase Detailed EI Basic Design Design Generation Debug FAT SAT Commissioning Phase Commissioning FF Pilot System Setup FF System Design Training For EPCs FF Training (External) FF Pilot System FF Test Bench Setup for FAT FF Training (Internal) FF Pilot System FF Device HIST Test Progress Report Device Selection & Evaluation Team Tech. Core Team Setup FF Data Exchange Mechanism Specification Dedicated FF Specification FF Requirement Review FF Loop Check Guideline FF Site Workshop FF Engineering Methodology Briefing (Internal & External) 13

14 Dedicated Project FF Design Specification Ensure consistency across the entire project Minimise the design effort required by all parties Minimise the validation requirement Minimise commissioning related problem Simplify the overall Fieldbus implementation process especially for EPC Contractors 14

15 Dedicated Project FF Design Specification FF Application Maximize regulatory process control devices in all Zone 2 and safe area FF Hardware Selection Project common FF hardware component (power supply, cable, field termination block) Only from a list of approved device to ensure interoperability Critical Loop Definition Define 3 level of control loop criticality and their application for segment design Segment Design Max. 10 Device per segment to simplify segment loading validation and ensure segment performance Junction Box/Wiring Requirement 2 10-way FF termination blocks in each JB, similar to conventional 20 pair multi-core cable Trunk cable length 500 metres Spur cable length 75 metres 15

16 FF Data Exchange Mechanism Specification Data specific for FF engineering Host need to know more FF instrument data than conventional instrument Exchange milestone and responsible party Define progressive data transfer schedule Emphasize data quality to avoid re-work 16

17 ITK (Interoperability Test Kit) FF Device HIST Test Focus on Device Device ITK revision registered with Foundation HIST (Host Interoperability Support Test) Focus on Host and Combination of Device and Host Compliance of a list of FF technologies supported by Host 17

18 Importance of HIST FF Device HIST Test Real problem exists in the combination of devices and a host Device fully tested with Host provide best value for end user What Yokogawa Did Set up FF laboratories in Yokogawa Headquarter Run the HIST program according to the FF specification Conduct HIST in cooperation with other device manufacturers for all FF devices selected for project use. Host System FF I/O Module DCS Builder PRM 18

19 Today s HIST Result All Yokogawa and 98 non-yokogawa device passed Yokogawa HIST 19

20 FF Pilot System FF Pilot System Architecture 20

21 FF Pilot System Mini-system includes all system components Selected project FF Device Configuration Tools Other related Automation Systems Prove MAC design, engineering, configuration, testing and commissioning methodology For testing all type of FF devices during FAT Use Pilot System to train EPCs and Owners 21

22 FF Training Classroom/Seminar Training MAC engineering team EPC engineering team CSPC operation team Hands-on training on FF Pilot System Gain practical experience Familiarize and refine procedures 22

23 FF Site Workshop Organize by CSPC with all EPC contractors Prepare for commissioning stage Highlight the critical issues for smooth FF commissioning Provide recommendations to all EPC FF Device Pre-installation Check Pre-Loop Check Loop Check 23

24 FF Loop Check Guideline Difference from conventional Loop Check No longer connectivity check No longer 1 to 1 device hook up Each segment, each FF device is a communication test Many parameters to be verified Device Tag Address Device Type and Revision 24

25 FF Loop Check Guideline Segment hook-up procedures 25

26 FF Loop Check Guideline Define common methodology among all EPC FF-H1 network check Parameters to be verified Segment power-on Initial segment download Tag verification Test Tools Usage 26

27 PRM for FIAT (Final Instrument Acceptance Test) Great Tools to reveal Full Instrument Status at Control Room Device Viewer - All FF Device Diagnosis Device Status Device Diagnostic Hardware Information Alarm Number Transducer Status Parameters of related Diagnostic 27

28 PRM for FIAT (Final Instrument Acceptance Test) Plug-in Application - Valve Calibration and Diagnosis 28

29 Success Factors Communications and Engagement with EPCs are vital Early Training to EPCs and Owner Engineers and Technicians to increase awareness Limit the types of vendor devices to avoid schedule overrun PRM is a very useful tool for commissioning Control of FF devices revisions 29

30 Keys for Large Scale FF Project in Future Thorough understanding of FF technology, including difference from conventional technology Well defined project requirement Use proven engineering methodology Strong core engineering team Emphasize full integration between FF Device and Control Systems 30

31 Thank You 31